Adapter assembly for interconnecting electromechanical surgical devices and surgical loading units, and surgical systems thereof

ABSTRACT

The present disclosure relates to adapter assemblies for use with and to electrically and mechanically interconnect electromechanical surgical devices and surgical loading units, and to surgical systems including hand held electromechanical surgical devices and adapter assemblies for connecting surgical loading units to the hand held electromechanical surgical devices.

CROSS-REFERENCE TO RELATED APPLICATIONS

The Present Application is a Continuation Application which claims thebenefit of and priority to U.S. patent application Ser. No. 14/822,970,filed on Aug. 11, 2015, which is a Continuation-in-Part Applicationclaiming the benefit of and priority to each of U.S. patent applicationSer. No. 14/550,071, filed on Nov. 21, 2014, (now U.S. Pat. No.9,918,713), which claims the benefit of and priority to U.S. ProvisionalPatent Application Ser. No. 61/913,550, filed on Dec. 9, 2013; and is aContinuation-in-Part of U.S. patent application Ser. No. 14/550,183,filed on Nov. 21, 2014, which claims the benefit of and priority to U.S.Provisional Application Ser. No. 61/913,572, filed on Dec. 9, 2013, theentire contents of each of which are incorporated herein by reference.

BACKGROUND Technical Field

The present disclosure relates to adapter assemblies for use in surgicalsystems. More specifically, the present disclosure relates to adapterassemblies for use with and to electrically and mechanicallyinterconnect electromechanical surgical devices and surgical loadingunits, and to surgical systems including hand held electromechanicalsurgical devices and adapter assemblies for connecting surgical loadingunits to the hand held electromechanical surgical devices.

2. BACKGROUND OF RELATED ART

A number of surgical device manufacturers have developed product lineswith proprietary drive systems for operating and/or manipulatingelectromechanical surgical devices. In many instances theelectromechanical surgical devices include a handle assembly, which isreusable, and disposable loading units and/or single use loading unitsor the like that are selectively connected to the handle assembly priorto use and then disconnected from the handle assembly following use inorder to be disposed of or in some instances sterilized for re-use.

In certain instances, an adapter assembly is used to interconnect anelectromechanical surgical device with any one of a number of surgicalloading units to establish a mechanical and/or electrical connectiontherebetween. By using an adapter assembly to interconnect theelectromechanical surgical device with the surgical loading units, anoverall length of this electromechanical surgical system tends to berelatively greater/longer as compared to an electromechanical surgicalsystem not using an adapter assembly. This increased length of theelectromechanical surgical system (including an adapter assembly) tendsto move a center of gravity of the electromechanical surgical system(including an adapter assembly) relatively distal of a center of gravityof another electromechanical surgical system (not including an adapterassembly).

With the center of gravity being located at a more distal location ofthe electromechanical surgical system, a torque exerted on the hand,wrist and arm of the user is increased and thus renders use of theelectromechanical surgical system tiresome or cumbersome.

Accordingly, a need exists for an adapter assembly that has a relativelyshorter length and that reduces the distal displacement of a center ofgravity of the electromechanical surgical system.

SUMMARY

The present disclosure relates to adapter assemblies for use with and toelectrically and mechanically interconnect electromechanical surgicaldevices and surgical loading units, and to surgical systems includinghand held electromechanical surgical devices and adapter assemblies forconnecting surgical loading units to the hand held electromechanicalsurgical devices.

According to an aspect of the present disclosure, an adapter assemblyfor selectively interconnecting a surgical loading unit that isconfigured to perform a function and a surgical device that isconfigured to actuate the loading unit, is provided. The loading unitmay include at least one axially translatable drive member, and thesurgical device may include at least one rotatable drive shaft. Theadapter assembly may include a housing configured and adapted forconnection with the surgical device and configured and adapted to be inoperative communication with each rotatable drive shaft of the surgicaldevice; an outer tube having a proximal end supported by the housing anda distal end configured and adapted for connection with the loadingunit, wherein the distal end of the outer tube is in operativecommunication with each of the axially translatable drive member of theloading unit; and the force/rotation transmitting/converting assemblyfor interconnecting a respective one drive shaft of the surgical deviceand a respective one axially translatable drive member of the loadingunit. The force/rotation transmitting/converting assembly may include aproximal rotation receiving member that is connectable to the respectivedrive shaft of the surgical device defining a threaded distal end; and adistal force transmitting member that is connectable to an articulationlink of the axially translatable drive member of the loading unit. Thedistal force transmitting member may include a bearing assembly havingan outer race threadably connected to the threaded distal end of theproximal drive shaft and an inner race; a distal articulation bar havinga proximal end and a distal end, the distal end of the distalarticulation bar being configured to selectively engage the axiallytranslatable drive member of the loading unit; a proximal articulationbar having a proximal end and a distal end, the distal end of theproximal articulation bar being secured to the proximal end of thedistal articulation bar; and a collar integrally supported at theproximal end of the proximal articulation bar, the collar having anouter diameter substantially equal to an outer diameter of the innerrace of the bearing assembly; wherein the force/rotationtransmitting/converting assembly converts and transmits a rotation ofthe rotatable drive shaft of the surgical device to an axial translationof the axially translatable drive member of the loading unit.

The proximal articulation bar may include a transition portionintegrally supporting the collar at a proximal end thereof and a bodyportion at a distal end thereof, the transition portion defining anouter diameter that is greater than an outer diameter of the bodyportion.

The outer diameter of the collar may be greater than the outer diameterof the transition portion such that the distal articulation bar and theproximal articulation bar resist bending during use.

The distal end of the proximal articulation bar may define a cut-outconfigured for mating with the proximal end of the distal articulationbar.

The outer race of the bearing assembly may include a first through holeand a second through hole, the first and second through holesintersecting to define a cavity in the outer race configured for housinga ball having a threaded bore formed therein, the threaded boreconfigured for threadably connecting to the threaded distal end of theproximal drive shaft.

According to another aspect of the present disclosure, an adapterassembly for selectively interconnecting a surgical loading unit that isconfigured to perform a function and a surgical device that isconfigured to actuate the loading unit, is provided. The loading unitmay include at least one axially translatable drive member, and thesurgical device may include at least one rotatable drive shaft. Theadapter assembly may include a housing configured and adapted forconnection with the surgical device and configured and adapted to be inoperative communication with each rotatable drive shaft of the surgicaldevice; an outer tube having a proximal end supported by the housing anda distal end configured and adapted for connection with the loadingunit, wherein the distal end of the outer tube is in operativecommunication with each of the axially translatable drive member of theloading unit; and the force/rotation transmitting/converting assemblyfor interconnecting a respective one drive shaft of the surgical deviceand a respective one axially translatable drive member of the loadingunit. The force/rotation transmitting/converting assembly may include aproximal rotation receiving member that is connectable to a respectiverotatable drive shaft of the surgical device, the proximal rotationreceiving member defining a threaded distal end; and a distal forcetransmitting member that is connectable to an articulation link of theaxially translatable drive member of the loading unit. The distal forcetransmitting member may include an articulation bar extendinglongitudinally between a proximal end and a distal end, the distal endof the articulation bar being configured to selectively engage theaxially translatable drive member of the loading unit; a bearingassembly having an outer race threadably connected to the threadeddistal end of the proximal drive shaft, and an inner race; and an innersleeve supported in the inner race of the bearing assembly and extendingaxially from the inner race, the inner sleeve including an innerdiameter and an outer diameter, the outer diameter defining a slotconfigured for disposal of the proximal end of the articulation bar suchthat the proximal end of the articulation bar is disposed between theinner race of the bearing assembly and the outer diameter of the innersleeve; wherein the force/rotation transmitting/converting assemblyconverts and transmits a rotation of the rotatable drive shaft of thesurgical device to an axial translation of the axially translatabledrive member of the loading unit.

The housing may include a slip ring cannula disposed within the innersleeve such that an outer diameter of the slip ring cannula engages theinner diameter of the inner sleeve utilizing an interference fit.

The outer race of the bearing assembly may include a first through holeand a second through hole, the first and second through holesintersecting to define a cavity in the outer race configured for housinga ball having a threaded bore formed therein, the threaded boreconfigured for threadably connecting to the threaded distal end of theproximal drive shaft.

According to another aspect of the present disclosure, an adapterassembly for selectively interconnecting a surgical loading unit that isconfigured to perform a function and a surgical device that isconfigured to actuate the loading unit, is provided. The loading unitmay include at least one axially translatable drive member, and thesurgical device may include at least one rotatable drive shaft. Theadapter assembly may include a housing configured and adapted forconnection with the surgical device and configured and adapted to be inoperative communication with each rotatable drive shaft of the surgicaldevice; an outer tube having a proximal end supported by the housing anda distal end configured and adapted for connection with the loadingunit, wherein the distal end of the outer tube is in operativecommunication with each of the axially translatable drive member of theloading unit; and the force/rotation transmitting/converting assemblyfor interconnecting a respective one drive shaft of the surgical deviceand a respective one axially translatable drive member of the loadingunit. The at least one force/rotation transmitting/converting assemblymay include a proximal rotation receiving member that is connectable toa respective rotatable drive shaft of the surgical device, the proximalrotation receiving member defining at least one spur gear; a driverincluding an outer surface defining at least one spur gear configuredfor mating with the spur gear of the proximal rotation receiving member,the driver defining a bore therethrough, the bore having an innersurface defining at least one thread; and a distal force transmittingmember that is connectable to an articulation link of the axiallytranslatable drive member of the loading unit. The distal forcetransmitting member may include a sleeve having an outer surfacedefining at least one thread configured to mate with the inner surfaceof the driver; and an articulation bar having a proximal end secured tothe sleeve and a distal end configured to selectively engage the axiallytranslatable drive member of the loading unit; wherein theforce/rotation transmitting/converting assembly converts and transmits arotation of the rotatable drive shaft of the surgical device to arotation of the driver such that the sleeve of the distal forcetransmitting member is axially translated resulting in an axialtranslation of the axially translatable drive member of the loadingunit.

The housing may include a distal plate having a first through holeconfigured for locating a distal boss of the driver such that the driveris mounted co-axial to the longitudinal axis.

The distal plate may include a second through hole configured forlocating a distal protrusion of the proximal rotation receiving membersuch that when the distal boss of the driver is located in the firstthrough hole and the distal protrusion of the proximal rotationreceiving member is located in the second through hole, the at least onespur gear of the driver is mated with the at least one spur gear of theproximal rotation receiving member.

The housing may define a proximal core portion configured for location aproximal boss of the driver such that the driver is mounted co-axial tothe longitudinal axis.

The sleeve defines a bore therethrough which defines an inner surface,and wherein the proximal end of the articulation bar is secured to theinner surface of the sleeve.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure are described herein withreference to the accompanying drawings, wherein:

FIG. 1A is a perspective view of an adapter assembly, in accordance withan embodiment of the present disclosure, interconnected between anexemplary electromechanical surgical device and an end effectorassembly;

FIG. 1B is a perspective view illustrating an attachment of a proximalend of the adapter assembly to a distal end of the electromechanicalsurgical device;

FIG. 2A is a front, perspective view of the adapter assembly of thepresent disclosure;

FIG. 2B is a rear, perspective view of the adapter assembly of FIG. 2A;

FIG. 3 is a top plan view of the adapter assembly of FIGS. 2A and 2B;

FIG. 4 is a side, elevational view of the adapter assembly of FIGS. 2Aand 2B;

FIG. 5 is a rear, perspective view of the adapter assembly of FIGS. 2Aand 2B, with some parts thereof separated;

FIG. 6 is a rear, perspective view of the adapter assembly of FIGS. 2Aand 2B, with most parts thereof separated;

FIG. 7 is a perspective view of an articulation assembly of the adapterassembly of FIGS. 2A and 2B;

FIG. 8 is an enlarged, perspective view, with parts separated, of thearticulation assembly of FIG. 7;

FIG. 9 is a perspective view of the articulation assembly of FIG. 7,shown in a first orientation;

FIG. 10 is a perspective view of the articulation assembly of FIG. 7,shown in a second orientation;

FIG. 11 is a cross-sectional view as taken along section line 11-11 ofFIG. 9;

FIG. 12 is a perspective view of an electrical assembly of the adapterassembly of FIGS. 2A and 2B;

FIG. 13 is a perspective view of the electrical assembly of FIG. 12shown connected to the core housing of the adapter assembly of FIGS. 2Aand 2B;

FIG. 14 is a cross-sectional view as taken along section line 14-14 ofFIG. 13;

FIG. 15 is a perspective view of a slip ring cannula or sleeve of theadapter assembly of FIGS. 2A and 2B;

FIG. 16 is an enlarged view of the indicated area of detail of FIG. 2B,illustrating an inner housing assembly of the adapter assembly of FIGS.2A and 2B;

FIG. 17 is a rear, perspective view of the inner housing assembly ofFIG. 16 with an outer knob housing half-section and a proximal capremoved therefrom;

FIG. 18 is a rear, perspective view of the inner housing assembly ofFIG. 16 with the outer knob housing, the proximal cap and a bushingplate removed therefrom;

FIG. 19 is a rear, perspective view of the inner housing assembly ofFIG. 16 with the outer knob housing, the proximal cap, the bushing plateand an inner housing removed therefrom;

FIG. 20 is a rear, perspective view of the an alternative embodiment ofinner housing assembly similar to that shown in FIG. 16 with the outerknob housing and the proximal inner housing removed therefrom;

FIG. 21 is a rear, perspective view of the inner housing assembly ofFIG. 20 with the outer knob housing, the proximal inner housing and thearticulation assembly removed therefrom;

FIG. 22 is a front, perspective view of the inner housing assembly ofFIG. 20 with the outer knob housing, the proximal inner housing and thearticulation assembly removed therefrom;

FIG. 23 is a front, perspective view of the inner housing assembly ofFIG. 20 with the outer knob housing and the proximal inner housingremoved therefrom;

FIG. 24 is a cross-sectional view as taken along section line 24-24 ofFIG. 2B;

FIG. 25 is an enlarged view of the indicated area of detail of FIG. 24;

FIG. 26 is an enlarged view of the indicated area of detail of FIG. 24,illustrating a lock button being actuated in a proximal direction;

FIG. 27 is a cross-sectional view as taken along section line 27-27 ofFIG. 2B;

FIG. 28 is a cross-sectional view as taken along section line 27-27 ofFIG. 2B, illustrating actuation of the articulation assembly in a distaldirection;

FIG. 29 is a cross-sectional view as taken along section line 29-29 ofFIG. 28;

FIG. 30 is a cross-sectional view as taken along section line 30-30 ofFIG. 28;

FIG. 31 is a cross-sectional view as taken along section line 31-31 ofFIG. 28;

FIG. 32 is a rear, perspective view of a proximal inner housing hubaccording to the present disclosure;

FIG. 33 is a front, perspective view of the proximal inner housing hubof FIG. 32;

FIG. 34 is a front, perspective view of the proximal inner housing hubof FIGS. 32 and 33 illustrating a first and a second force/rotationtransmitting/converting assembly and a reinforcing assembly associatedtherewith;

FIG. 35 is a front, perspective view of a plate bushing of the proximalinner housing assembly of the present disclosure;

FIG. 36 is a rear, perspective view of the plate bushing of FIG. 35;

FIG. 37 is a rear, perspective view of the proximal inner housingassembly illustrating the plate bushing of FIGS. 35 and 36 attachedthereto;

FIG. 38 is a rear, perspective view of the proximal inner housingassembly of FIG. 37 with connector sleeves removed therefrom;

FIG. 39 is a rear, perspective view of the proximal inner housingassembly of FIG. 37 with connector sleeves removed therefrom and theplate bushing shown in phantom;

FIG. 40 is a rear, perspective view of the proximal inner housingassembly of FIG. 37 with connector sleeves removed therefrom;

FIG. 41 is a rear, perspective of the inner housing assembly of FIG. 37illustrating a support plate, according to another embodiment of thepresent disclosure, coupled thereto;

FIG. 42 is a rear, perspective of the inner housing assembly of FIG. 41with the support plate removed therefrom;

FIG. 43 is a front, perspective view of an inner housing assemblyaccording to another embodiment of the present disclosure with the outerknob housing, the proximal inner housing removed therefrom;

FIG. 44 is a rear, perspective view of the inner housing assembly ofFIG. 43 with the outer knob housing, the proximal inner housing and thearticulation assembly removed therefrom;

FIG. 45 is a perspective view of a bracket assembly of the inner housingassembly of FIGS. 43 and 44;

FIG. 46 is a perspective view of a reinforcing sleeve for use with theinner housing assembly of FIGS. 43 and 44;

FIG. 47 is a perspective view of the inner housing assembly of FIGS. 43and 44, illustrating the reinforcing sleeve of FIG. 46 supportedthereon;

FIG. 48 is a perspective view, with parts separated, of an exemplaryloading unit for use with the surgical device and the adapter of thepresent disclosure;

FIG. 49 is a perspective view of an alternative embodiment of anarticulation assembly of the adapter assembly of FIGS. 2A and 2B;

FIG. 50 is a perspective view of a bearing assembly of the articulationassembly of FIG. 49;

FIG. 51 is a perspective, cutaway view of the bearing assembly of FIG.50, with a bearing housing removed therefrom;

FIG. 52 is a perspective view of the bearing assembly of FIG. 50including a proximal drive shaft;

FIG. 53 is a perspective view of an alternative embodiment of an innerhousing assembly similar to that shown in FIG. 16 with the outer knobhousing and the proximal inner housing removed therefrom;

FIG. 54 is a perspective view of another alternative embodiment of anarticulation assembly of the adapter assembly of FIGS. 2A and 2B;

FIG. 55 is a perspective view of a bearing assembly of the articulationassembly of FIG. 54;

FIG. 56 is a cross-sectional view of an inner housing assembly similarto that shown in FIG. 53 taken along section line 56-56 of FIG. 53;

FIG. 57 is a rear perspective view of yet another alternative embodimentof a bearing assembly similar to those shown in FIGS. 50 and 55; and

FIG. 58 is a perspective view of still another alternative embodiment ofan articulation assembly of the adapter assembly of FIGS. 2A and 2B.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed surgical devices, adapterassemblies, and loading unit detection assemblies for surgical devicesand/or handle assemblies are described in detail with reference to thedrawings, in which like reference numerals designate identical orcorresponding elements in each of the several views. As used herein theterm “distal” refers to that portion of the adapter assembly or surgicaldevice, or component thereof, farther from the user, while the term“proximal” refers to that portion of the adapter assembly or surgicaldevice, or component thereof, closer to the user.

A surgical device, in accordance with an embodiment of the presentdisclosure, is generally designated as 100, and is in the form of apowered hand held electromechanical instrument configured for selectiveattachment thereto of a plurality of different end effectors that areeach configured for actuation and manipulation by the powered hand heldelectromechanical surgical instrument.

As illustrated in FIG. 1A, surgical device 100 is configured forselective connection with an adapter assembly 200, and, in turn, adapterassembly 200 is configured for selective connection with a loading unit300 (e.g., an end effector, multiple- or single-use loading unit, seeFIG. 48). Surgical device 100 and adapter assembly 200, together, maycomprise an electromechanical surgical system that is configured andadapted to selectively connect with a loading unit 300 and to actuateloading unit 300.

As illustrated in FIGS. 1A and 1B, surgical device 100 includes a handlehousing 102 including a circuit board (not shown) and a drive mechanism(not shown) is situated therein. The circuit board is configured tocontrol the various operations of surgical device 100. Handle housing102 defines a cavity therein (not shown) for selective removable receiptof a rechargeable battery (not shown) therein. The battery is configuredto supply power to any of the electrical components of surgical device100.

Handle housing 102 includes an upper housing portion 102 a which housesvarious components of surgical device 100, and a lower hand grip portion102 b extending from upper housing portion 102 a. Lower hand gripportion 102 b may be disposed distally of a proximal-most end of upperhousing portion 102 a. The location of lower housing portion 102 brelative to upper housing portion 102 a is selected to balance a weightof a surgical device 100 that is connected to or supporting adapterassembly 200 and/or end effector 300.

Handle housing 102 provides a housing in which the drive mechanism issituated. The drive mechanism is configured to drive shafts and/or gearcomponents in order to perform the various operations of surgical device100. In particular, the drive mechanism is configured to drive shaftsand/or gear components in order to selectively move a tool assembly 304of loading unit 300 (see FIGS. 1 and 48) relative to a proximal bodyportion 302 of loading unit 300, to rotate loading unit 300 about alongitudinal axis “X” (see FIG. 1A) relative to handle housing 102, tomove/approximate an anvil assembly 306 and a cartridge assembly 308 ofloading unit 300 relative to one another, and/or to fire a stapling andcutting cartridge within cartridge assembly 308 of loading unit 300.

As illustrated in FIG. 1B, handle housing 102 defines a connectingportion 108 configured to accept a corresponding drive coupling assembly210 of adapter assembly 200. Specifically, connecting portion 108 ofsurgical device 100 has a recess 108 a that receives a proximal cap 210a (FIG. 6) of drive coupling assembly 210 of adapter assembly 200 whenadapter assembly 200 is mated to surgical device 100. Connecting portion108 houses three rotatable drive connectors 118, 120, 122 which arearranged in a common plane or line with one another.

When adapter assembly 200 is mated to surgical device 100, each ofrotatable drive connectors 118, 120, 122 of surgical device 100 coupleswith a corresponding rotatable connector sleeve 218, 220, 222 of adapterassembly 200. (see FIG. 1B). In this regard, the interface betweencorresponding first drive connector 118 and first connector sleeve 218,the interface between corresponding second drive connector 120 andsecond connector sleeve 220, and the interface between correspondingthird drive connector 122 and third connector sleeve 222 are keyed suchthat rotation of each of drive connectors 118, 120, 122 of surgicaldevice 100 causes a corresponding rotation of the correspondingconnector sleeve 218, 220, 222 of adapter assembly 200.

The mating of drive connectors 118, 120, 122 of surgical device 100 withconnector sleeves 218, 220, 222 of adapter assembly 200 allowsrotational forces to be independently transmitted via each of the threerespective connector interfaces. The drive connectors 118, 120, 122 ofsurgical device 100 are configured to be independently rotated by thedrive mechanism of surgical device 100. In this regard, a functionselection module (not shown) of the drive mechanism selects which driveconnector or connectors 118, 120, 122 of surgical device 100 is to bedriven by the motor of surgical device 100.

Since each of drive connectors 118, 120, 122 of surgical device 100 hasa keyed and/or substantially non-rotatable interface with respectiveconnector sleeves 218, 220, 222 of adapter assembly 200, when adapterassembly 200 is coupled to surgical device 100, rotational force(s) areselectively transferred from drive connectors of surgical device 100 toadapter assembly 200.

The selective rotation of drive connector(s) 118, 120 and/or 122 ofsurgical device 100 allows surgical device 100 to selectively actuatedifferent functions of loading unit 300. For example, selective andindependent rotation of first drive connector 118 of surgical device 100corresponds to the selective and independent opening and closing of toolassembly 304 of loading unit 300, and driving of a stapling/cuttingcomponent of tool assembly 304 of loading unit 300. As an additionalexample, the selective and independent rotation of second driveconnector 120 of surgical device 100 corresponds to the selective andindependent articulation of tool assembly 304 of loading unit 300transverse to longitudinal axis “X” (see FIG. 1A). Additionally, forinstance, the selective and independent rotation of third driveconnector 122 of surgical device 100 corresponds to the selective andindependent rotation of loading unit 300 about longitudinal axis “X”(see FIG. 1A) relative to handle housing 102 of surgical device 100.

As illustrated in FIG. 1A, handle housing 102 supports a plurality offinger-actuated control buttons, rocker devices and the like foractivating various functions of surgical device 100.

Reference may be made to International Application No.PCT/US2008/077249, filed Sep. 22, 2008 (Inter. Pub. No. WO 2009/039506)and U.S. patent application Ser. No. 12/622,827, filed on Nov. 20, 2009,the entire content of each of which being incorporated herein byreference, for a detailed description of various internal components ofand operation of exemplary electromechanical, hand-held, poweredsurgical instrument 100.

Turning now to FIGS. 1A-47, adapter assembly 200 includes an outer knobhousing 202 and an outer tube 206 extending from a distal end of knobhousing 202. Knob housing 202 and outer tube 206 are configured anddimensioned to house the components of adapter assembly 200. Outer tube206 is dimensioned for endoscopic insertion, in particular, that outertube is passable through a typical trocar port, cannula or the like.Knob housing 202 is dimensioned to not enter the trocar port, cannula ofthe like. Knob housing 202 is configured and adapted to connect toconnecting portion 108 of handle housing 102 of surgical device 100.

Adapter assembly 200 is configured to convert a rotation of either ofdrive connectors 118 and 120 of surgical device 100 into axialtranslation useful for operating a drive assembly 360 and anarticulation link 366 of loading unit 300, as illustrated in FIG. 48 andas will be described in greater detail below. As illustrated in FIGS. 5,6, 13, 14, 17, 18, 20, 25-34 and 37-40, adapter assembly 200 includes aproximal inner housing assembly 204 rotatably supporting a firstrotatable proximal drive shaft 212, a second rotatable proximal driveshaft 214, and a third rotatable proximal drive shaft 216 therein. Eachproximal drive shaft 212, 214, 216 functions as a rotation receivingmember to receive rotational forces from respective drive shafts ofsurgical device 100, as described in greater detail below.

As described briefly above, inner housing assembly 204 of shaft assembly200 is also configured to rotatably support first, second and thirdconnector sleeves 218, 220 and 222, respectively, arranged in a commonplane or line with one another. Each of connector sleeves 218, 220, 222is configured to mate with respective first, second and third driveconnectors 118, 120, 122 of surgical device 100, as described above.Each of connector sleeves 218, 220, 222 is further configured to matewith a proximal end of respective first, second and third proximal driveshafts 212, 214, 216.

Inner housing assembly 204 also includes, as illustrated in FIGS. 6, 17,27 and 28, a first, a second and a third biasing member 224, 226 and 228disposed distally of respective first, second and third connectorsleeves 218, 220, 222. Each of biasing members 224, 226 and 228 isdisposed about respective first, second and third rotatable proximaldrive shaft 212, 214 and 216. Biasing members 224, 226 and 228 act onrespective connector sleeves 218, 220 and 222 to help maintain connectorsleeves 218, 220 and 222 engaged with the distal end of respective driverotatable drive connectors 118, 120, 122 of surgical device 100 whenadapter assembly 200 is connected to surgical device 100.

In particular, first, second and third biasing members 224, 226 and 228function to bias respective connector sleeves 218, 220 and 222 in aproximal direction. In this manner, during assembly of adapter assembly200 to surgical device 100, if first, second and or third connectorsleeves 218, 220 and/or 222 is/are misaligned with the drive connectors118, 120, 122 of surgical device 100, first, second and/or third biasingmember(s) 224, 226 and/or 228 are compressed. Thus, when surgical device100 is operated, drive connectors 118, 120, 122 of surgical device 100will rotate and first, second and/or third biasing member(s) 224, 226and/or 228 will cause respective first, second and/or third connectorsleeve(s) 218, 220 and/or 222 to slide back proximally, effectivelycoupling drive connectors 118, 120, 122 of surgical device 100 to first,second and/or third proximal drive shaft(s) 212, 214 and 216 of innerhousing assembly 204.

Adapter assembly 200 includes a plurality of force/rotationtransmitting/converting assemblies, each disposed within inner housingassembly 204 and outer tube 206. Each force/rotationtransmitting/converting assembly is configured and adapted totransmit/convert a speed/force of rotation (e.g., increase or decrease)of first, second and third rotatable drive connectors 118, 120 and 122of surgical instrument 100 before transmission of such rotationalspeed/force to loading unit 300.

Specifically, as illustrated in FIG. 6, adapter assembly 200 includes afirst, a second and a third force/rotation transmitting/convertingassembly 240, 250, 260, respectively, disposed within inner housing 208and outer tube 206. Each force/rotation transmitting/converting assembly240, 250, 260 is configured and adapted to transmit or convert arotation of a first, second and third drive connector 118, 120, 122 ofsurgical device 100 into axial translation of articulation bar 258 ofadapter assembly 200, to effectuate articulation of loading unit 300; arotation of a ring gear 266 of adapter assembly 200, to effectuaterotation of adapter assembly 200; or axial translation of a distal drivemember 248 of adapter assembly 200 to effectuate closing, opening andfiring of loading unit 300.

As shown in FIGS. 5, 6 and 24-31, first force/rotationtransmitting/converting assembly 240 includes first rotatable proximaldrive shaft 212, which, as described above, is rotatably supportedwithin inner housing assembly 204. First rotatable proximal drive shaft212 includes a non-circular proximal end portion configured forconnection with first connector 218 which is connected to respectivefirst connector 118 of surgical device 100. First rotatable proximaldrive shaft 212 includes a distal end portion 212 b having a threadedouter profile or surface.

First force/rotation transmitting/converting assembly 240 furtherincludes a drive coupling nut 244 rotatably coupled to threaded distalend portion 212 b of first rotatable proximal drive shaft 212, and whichis slidably disposed within outer tube 206. Drive coupling nut 244 isslidably keyed within proximal core tube portion of outer tube 206 so asto be prevented from rotation as first rotatable proximal drive shaft212 is rotated. In this manner, as first rotatable proximal drive shaft212 is rotated, drive coupling nut 244 is translated along threadeddistal end portion 212 b of first rotatable proximal drive shaft 212and, in turn, through and/or along outer tube 206.

First force/rotation transmitting/converting assembly 240 furtherincludes a distal drive member 248 that is mechanically engaged withdrive coupling nut 244, such that axial movement of drive coupling nut244 results in a corresponding amount of axial movement of distal drivemember 248. The distal end portion of distal drive member 248 supports aconnection member 247 configured and dimensioned for selectiveengagement with a drive member 374 of drive assembly 360 of loading unit300 (FIG. 48). Drive coupling nut 244 and/or distal drive member 248function as a force transmitting member to components of loading unit300, as described in greater detail below.

In operation, as first rotatable proximal drive shaft 212 is rotated,due to a rotation of first connector sleeve 218, as a result of therotation of the first respective drive connector 118 of surgical device100, drive coupling nut 244 is caused to be translated axially alongfirst distal drive shaft 242. As drive coupling nut 244 is caused to betranslated axially along first distal drive shaft 242, distal drivemember 248 is caused to be translated axially relative to outer tube206. As distal drive member 248 is translated axially, with connectionmember 247 connected thereto and engaged with drive member 374 of driveassembly 360 of loading unit 300 (FIG. 47), distal drive member 248causes concomitant axial translation of drive member 374 of loading unit300 to effectuate a closure of tool assembly 304 and a firing of toolassembly 304 of loading unit 300.

With reference to FIGS. 5-11, 19 and 23-31, second drive converterassembly 250 of adapter assembly 200 includes second proximal driveshaft 214 rotatably supported within inner housing assembly 204. Secondrotatable proximal drive shaft 214 includes a non-circular proximal endportion configured for connection with second connector or coupler 220which is connected to respective second connector 120 of surgical device100. Second rotatable proximal drive shaft 214 further includes a distalend portion 214 b having a threaded outer profile or surface.

Distal end portion 214 b of proximal drive shaft 214 is threadablyengaged with an articulation bearing housing 252 a of an articulationbearing assembly 252. Articulation bearing assembly 252 includes ahousing 252 a supporting an articulation bearing 253 having an innerrace 253 b that is independently rotatable relative to an outer race 253a. Articulation bearing housing 252 a has a non-circular outer profile,for example tear-drop shaped, that is slidably and non-rotatablydisposed within a complementary bore 204 c (FIGS. 25, 26, 29 and 33) ofinner housing hub 204 a.

Second drive converter assembly 250 of adapter assembly 200 furtherincludes an articulation bar 258 having a proximal portion 258 a securedto inner race 253 b of articulation bearing 253. A distal portion 258 bof articulation bar 258 includes a slot 258 c therein, which isconfigured to accept a portion 366, e.g., a flag, articulation link(FIG. 47) of loading unit 300. Articulation bar 258 functions as a forcetransmitting member to components of loading unit 300, as described ingreater detail below.

With further regard to articulation bearing assembly 252, articulationbearing assembly 252 is both rotatable and longitudinally translatable.Additionally, it is envisioned that articulation bearing assembly 252allows for free, unimpeded rotational movement of loading unit 300 whenits jaw members 306, 308 are in an approximated position and/or when jawmembers 306, 308 are articulated.

In operation, as second proximal drive shaft 214 is rotated due to arotation of second connector sleeve 220, as a result of the rotation ofthe second drive connector 120 of surgical device 100, articulationbearing assembly 252 is caused to be translated axially along threadeddistal end portion 214 b of second proximal drive shaft 214, which inturn causes articulation bar 258 to be axially translated relative toouter tube 206. As articulation bar 258 is translated axially,articulation bar 258, being coupled to articulation link 366 of loadingunit 300, causes concomitant axial translation of articulation link 366of loading unit 300 to effectuate an articulation of tool assembly 304.Articulation bar 258 is secured to inner race 253 b of articulationbearing 253 and is thus free to rotate about the longitudinal axis X-Xrelative to outer race 253 a of articulation bearing 253.

As illustrated in FIGS. 6, 17, 18, 20-23, 25-28, 31 and 37-40 and asmentioned above, adapter assembly 200 includes a third force/rotationtransmitting/converting assembly 260 supported in inner housing assembly204. Third force/rotation transmitting/converting assembly 260 includesa rotation ring gear 266 fixedly supported in and connected to outerknob housing 202. Ring gear 266 defines an internal array of gear teeth266 a (FIG. 6). Ring gear 266 includes a pair of diametrically opposed,radially extending protrusions 266 b (FIG. 6) projecting from an outeredge thereof. Protrusions 266 b are disposed within recesses defined inouter knob housing 202, such that rotation of ring gear 266 results inrotation of outer knob housing 202, and vice a versa.

Third force/rotation transmitting/converting assembly 260 furtherincludes third rotatable proximal drive shaft 216 which, as describedabove, is rotatably supported within inner housing assembly 204. Thirdrotatable proximal drive shaft 216 includes a non-circular proximal endportion configured for connection with third connector 222 which isconnected to respective third connector 122 of surgical device 100.Third rotatable proximal drive shaft 216 includes a spur gear 216 akeyed to a distal end thereof. A reversing spur gear 264 inter-engagesspur gear 216 a of third rotatable proximal drive shaft 216 to gearteeth 266 a of ring gear 266.

In operation, as third rotatable proximal drive shaft 216 is rotated,due to a rotation of third connector sleeve 222, as a result of therotation of the third drive connector 122 of surgical device 100, spurgear 216 a of third rotatable proximal drive shaft 216 engages reversinggear 264 causing reversing gear 264 to rotate. As reversing gear 264rotates, ring gear 266 also rotates thereby causing outer knob housing202 to rotate. As outer knob housing 202 is rotated, outer tube 206 iscaused to be rotated about longitudinal axis “X” of adapter assembly200. As outer tube 206 is rotated, loading unit 300, that is connectedto a distal end portion of adapter assembly 200, is also caused to berotated about a longitudinal axis of adapter assembly 200.

Adapter assembly 200 further includes, as seen in FIGS. 1B, 3-5, 16, 17,20 and 24-26, an attachment/detachment button 272 supported thereon.Specifically, button 272 is supported on drive coupling assembly 210 ofadapter assembly 200 and is biased by a biasing member 274 to anun-actuated condition. Button 272 includes lip or ledge 272 a formedtherewith that is configured to snap behind a corresponding lip or ledge108 b defined along recess 108 a of connecting portion 108 of surgicaldevice 100. In use, when adapter assembly 200 is connected to surgicaldevice 100, lip 272 a of button 272 is disposed behind lip 108 b ofconnecting portion 108 of surgical device 100 to secure and retainadapter assembly 200 and surgical device 100 with one another. In orderto permit disconnection of adapter assembly 200 and surgical device 100from one another, button 272 is depresses or actuated, against the biasof biasing member 274, to disengage lip 272 a of button 272 and lip 108b of connecting portion 108 of surgical device 100.

With reference to FIGS. 1A, 2A, 2B, 3-5 and 24-26, adapter assembly 200further includes a lock mechanism 280 for fixing the axial position andradial orientation of distal drive member 248. Lock mechanism 280includes a button 282 slidably supported on outer knob housing 202. Lockbutton 282 is connected to an actuation bar 284 that extendslongitudinally through outer tube 206. Actuation bar 284 moves upon amovement of lock button 282. Upon a predetermined amount of movement oflock button 282, a distal end of actuation bar 284 may move into contactwith a lock out (not shown), which causes the lock out to cam a cammingmember 288 (FIG. 24) from a recess 249 in distal drive member 248. Whencamming member 288 is in engagement with recess 249 (e.g., at leastpartially within recess 249, see FIGS. 6 and 24), the engagement betweencamming member 288 and distal drive member 248 effectively locks theaxial and rotational position of end effector 300 that is engaged withconnection member 247.

In operation, in order to lock the position and/or orientation of distaldrive member 248, a user moves lock button 282 from a distal position toa proximal position (FIGS. 25 and 26), thereby causing the lock out (notshown) to move proximally such that a distal face of the lock out movesout of contact with camming member 288, which causes camming member 288to cam into recess 249 of distal drive member 248. In this manner,distal drive member 248 is prevented from distal and/or proximalmovement. When lock button 282 is moved from the proximal position tothe distal position, the distal end of actuation bar 284 moves distallyinto the lock out, against the bias of a biasing member (not shown), toforce camming member 288 out of recess 249, thereby allowing unimpededaxial translation and radial movement of distal drive member 248.

Reference may be made to U.S. Pat. No. 9,597,104, the entire content ofwhich is incorporated herein by reference, for a more detaileddiscussion of the construction and operation of lock mechanism 280.

With reference to FIGS. 1B, 6, 12-15 and 25-28, adapter assembly 200includes an electrical assembly 290 supported on and in outer knobhousing 202 and inner housing assembly 204. Electrical assembly 290includes a plurality of electrical contact pins 292, supported on acircuit board 294, for electrical connection to a correspondingelectrical plug 190 disposed in connecting portion 108 of surgicaldevice 100. Electrical contacts 290 serve to allow for calibration andcommunication of life-cycle information to the circuit board of surgicaldevice 100 via electrical plugs 190 that are electrically connected tothe circuit board (not shown) of surgical device 100.

Electrical assembly 290 further includes a strain gauge 296 electricallyconnected to circuit board 294. Strain gauge 296 is provided with anotch 296 a which is configured and adapted to receive stem 204 d of hub204 a of inner housing assembly 204. Stem 204 d of hub 204 a functionsto restrict rotational movement of strain gauge 296. As illustrated inFIGS. 25-28, first rotatable proximal drive shaft 212 extends throughstrain gauge 296. Strain gauge 296 provides a closed-loop feedback to afiring/clamping load exhibited by first rotatable proximal drive shaft212.

Electrical assembly 290 also includes a slip ring 298 disposed core tubeof tube 206. Slip ring 298 is in electrical connection with circuitboard 294. Slip ring 298 functions to permit rotation of first rotatableproximal drive shaft 212 and axial translation of drive coupling nut 244while still maintaining electrical contact of electrical contact rings298 a thereof with at least another electrical component within adapterassembly 200, and while permitting the other electrical components torotate about first rotatable proximal drive shaft 212 and drive couplingnut 244

Electrical assembly 290 may include a slip ring cannula or sleeve 299positioned core tube of tube 206 to protect and/or shield any wiresextending from slip ring 298.

Turning now to FIGS. 6, 11, 14, 32 and 33, inner housing assembly 204has been designed to reduce incidents of racking of second proximaldrive shaft 214 as drive shaft 214 rotates to axially translatearticulation bearing assembly 252. Inner housing assembly 204 includes ahub 204 a having a distally oriented annular wall 204 b defining asubstantially circular outer profile, and defining a substantiallytear-drop shaped inner recess or bore 204 c. Bore 204 c of hub 204 a isshaped and dimensioned to slidably receive articulation bearing assembly252 therewithin.

Inner housing assembly 204 includes a ring plate 254 a (FIG. 34) securedto a distal face of distally oriented annular wall 204 b of hub 204 a.Plate 254 a defines an aperture 254 e therethrough that is sized andformed therein so as to be aligned with second proximal drive shaft 214and to rotatably receive a distal tip 214 c of second proximal driveshaft 214. In this manner, distal tip 214 c of second proximal driveshaft 214 is supported and prevented from moving radially away from alongitudinal rotational axis of second proximal drive shaft 214 assecond proximal drive shaft 214 is rotated to axially translatearticulation bearing assembly 252.

As illustrated in FIGS. 14, 32, 39 and 40, hub 204 a defines a feature(e.g., a stem or the like) 204 d projecting therefrom which functions toengage notch 296 a of strain gauge 296 of electrical assembly 290 tomeasure forces experienced by shaft 212 as surgical device 100 isoperated.

With reference to FIGS. 35-40, a plate bushing 230 of inner housingassembly 204 is shown and described. Plate bushing 230 extends acrosshub 204 a of inner housing assembly 204 and is secured to hub 204 a byfastening members. Plate bushing 230 defines three apertures 230 a, 230b, 230 c that are aligned with and rotatably receive respective first,second and third proximal drive shafts 212, 214, 216 therein. Platebushing 230 provides a surface against which first, second and thirdbiasing members 224, 226 and 228 come into contact or rest against.

While plate bushing 230 has been shown and described as being a unitarymonolithic piece, as illustrated in FIGS. 6 and 37-40, it is envisionedand within the scope of the present application that plate bushing 230may be separated into several parts including, and not limited to, asseen in FIGS. 40-42, a support plate 230′ extending across drive shafts212, 214, 216, and a separate bushing for each of drive shafts 212, 214,216 and disposed between the support plate 230′ and hub 204 a of innerhousing assembly 204. Support plate 230′ may include a pair of slots 230a′, 230 b′ formed therein, which are configured and adapted to receivetabs 296 b of strain gauge 296 that project axially therefrom.

Turning now to FIGS. 43-47, an inner housing assembly 204′ according toanother embodiment of the present disclosure is shown and will bedescribed. In order to reduce incidents of racking (i.e., distal end 214b of second proximal drive shaft 214 moving radially away from alongitudinal rotational axis thereof) of second proximal drive shaft 214as drive shaft 214 rotates to axially translate articulation bearingassembly 252, inner housing assembly 204′ may include a reinforcementframe or bracket assembly 254′. Bracket assembly 254′ includes a firstplate 254 a′ and a second plate 254 b′ integrally connected to andspaced a distance from first plate 254 a′ by a plurality of connectingrods 254 c′ extending therebetween.

First plate 254 a′ is disposed adjacent to or in close proximity to ringgear 266 and defines an aperture 254 d′ therethrough. Aperture 254 d′ issized and formed in first plate 254 a′ so as to be aligned with secondproximal drive shaft 214 and to permit second proximal drive shaft 214to freely rotate therewithin. Second plate 254 b′ is spaced from firstplate 254 a′ so as to be disposed at a distal free end of secondproximal drive shaft 214. Second plate 254 b′ defines an aperture 254 e′therethrough. Aperture 254 e′ is sized and formed in second plate orflange 254 b′ so as to be aligned with second proximal drive shaft 214and to rotatably receive a distal tip 214 c of second proximal driveshaft 214.

In this manner, distal tip 214 c of second proximal drive shaft 214 issupported and prevented from moving radially away from a longitudinalrotational axis of second proximal drive shaft 214 as second proximaldrive shaft 214 is rotated to axially translate articulation bearingassembly 252.

As illustrated in FIGS. 38, 46 and 47, inner housing assembly 204′ mayinclude a reinforcing sleeve 255′ disposed about bracket assembly 254′to further reinforce bracket assembly 254′. It is contemplated in anembodiment that reinforcing sleeve 255′ may be interposed between firstplate 254 a′ and second plate 254 b′ of bracket assembly 254′. It isfurther contemplated that reinforcing sleeve 255′ may be interposedbetween second plate 254 b′ and a distally oriented face of proximalinner housing assembly 204′.

Turning now to FIGS. 49-53, a force/rotation transmitting/convertingassembly 350, according to another embodiment of the present disclosure,is shown and will be described. Force/rotation transmitting/convertingassembly 350 is similar to the second force/rotationtransmitting/converting assembly 250 and is only described herein to theextent necessary to describe the differences in construction andoperation thereof. Likewise, another embodiment of an articulationbearing assembly is shown generally as 352. Articulation bearingassembly 352 is similar to articulation bearing assembly 252 and is onlydescribed herein to the extent necessary to describe the differences inconstruction and operation thereof.

With reference to FIGS. 49 and 52, force/rotationtransmitting/converting assembly 350 includes a distal forcetransmitting member 354 and a proximal drive shaft 314. Proximal driveshaft 314 is rotatably supported within an inner housing assembly 312(see FIG. 53). Proximal drive shaft 314 includes a distal portion 314 ahaving a threaded outer profile or surface and a non-circular proximalportion 314 b configured for mating with a respective drive connector120 of surgical device 100 (see FIG. 1B).

Distal force transmitting member 354 includes, an articulation bearingassembly 352, a distal articulation bar 358 a, a proximal articulationbar 358 b, and a collar 370. Articulation bearing assembly 352 includesa bearing housing 352 a supporting an articulation bearing 353. Inembodiments, bearing housing 352 a has a non-circular outer profile,such as, for example, a tear-drop shape.

In embodiments such as the one shown in FIG. 57, bearing housing 352 aincludes a racking assembly 380. Racking assembly 380 includes a firstthrough hole 382 a and a second through hole 382 b. First and secondthrough holes 382 a, 382 b intersect to define a cavity 382 c in bearinghousing 352 a. Cavity 382 c is configured to house a ball 384 having athreaded bore 384 a formed therein. The threaded bore 384 a of ball 384is configured to threadably connect to the threaded distal portion 314 aof the proximal drive shaft 314. In this embodiment, bearing housing 352a is able to or free to rack during actuation of the force/rotationtransmitting/converting assembly 350 without the stress from the rackingbeing transferred to the proximal drive shaft 314, thereby preventingbending of the proximal drive shaft 314.

With reference momentarily to FIG. 51, articulation bearing 353 includesan inner race 353 b that is independently rotatable relative to an outerrace 353 a about the longitudinal axis “X.” In embodiments, outer race353 a and inner race 353 b each defines a circular cross-section havingan inner diameter of “D1” and “D2” respectively, wherein inner diameter“D1” is greater than “D2.”

With reference back to FIG. 49, distal articulation bar 358 a includes abody portion 357 extending along longitudinal axis “X” between a distalend 357 a and a proximal end 357 b. Similarly, proximal articulation bar358 b includes a body portion 359 extending along longitudinal axis “X”between a distal end 359 a and a proximal end 359 b. Body portion 357 ofthe distal articulation bar 358 a includes an outer diameter “D3.”Similarly, body portion 359 of the proximal articular bar 358 b includesan outer diameter “D4,” wherein outer diameter “D3” is equal to outerdiameter “D4.”

In embodiments as shown in FIG. 49, distal end 359 a of the proximalarticulation bar 358 a defines a cut out 355 shaped for mating with theproximal end 357 b of the distal articulation bar 358 a. This enablesdistal end 359 a of proximal articulation bar 358 b to connect to theproximal end 357 b of the distal articulation bar 358 a. In embodiments,distal end 359 a of proximal articulation bar 358 b is welded toproximal end 357 b of the distal articulation bar 358 a. However, it isenvisioned that the distal and proximal articulation bars 358 a, 358 bmay be fixedly connected using adhesives. In embodiments, cut out 355 isshaped such that there is a gap “G” between the proximal end 357 b ofthe distal articulation bar 358 a and a proximal portion 355 a of cutout 355. Gap “G” enables distal end 357 a of the distal articulation bar358 a to be spaced from the articulation bearing 353 with greateraccuracy and repeatability within the tolerance.

Proximal articulation bar 358 b further includes a transition portion359 c extending proximally from proximal articulation bar 358 b.Transition portion 359 c includes an outer diameter “D5,” wherein outerdiameter “D5” is greater than outer diameter “D3” and outer diameter“D4.” As shown in FIG. 49, transition portion 359 c abuts collar 370. Ineffect, proximal articulation bar 358 b includes a body portion 359 thatextends proximally to transition portion 359 c, which extends proximallyto collar 370.

As shown in FIG. 51, collar 370 of distal force transmitting member 354includes a first portion 370 a having a first outer diameter “D6” and asecond portion 370 b having a second outer diameter “D7,” wherein firstouter diameter “D6” is greater than second outer diameter “D7.” Inembodiments, second portion 370 b is correspondingly sized with theinner race 353 b of the articulation bearing 353 such that the secondportion 370 b of collar 370 engages an inner surface (not shown) ofinner race 353 b of the articulation bearing 353. In these embodiments,first portion 370 a of collar 370 is larger than the inner race 353 b ofthe articulation bearing 353 such that only the second portion 370 b ofcollar 370 mates with the inner race 353 b of articulation bearing 353.

In some embodiments, collar 370 is affixed to articulation bearing 353by welding second portion 370 b of collar 370 to inner race 353 b ofarticulation bearing 353. In embodiments, a washer 353 c is welded to aproximal end 353 d of the articulation bearing 353 to further securecollar 370 to articulation bearing 353. As shown in FIG. 51, washer 353c has an outer diameter “D6′” equal to the first outer diameter “D6” ofthe first portion 370 a of collar 370 a. Washer 353 c has an innerdiameter “D8” which is greater than the second outer diameter “D7” ofthe second portion 370 b of collar 370 such that the second portion 370b of collar 370 engages an inner surface (not shown) of washer 353 c. Itis envisioned that washer 353 c can be secured to the proximal end 353 dof the articulation bearing 353 and second portion 370 b of collar 370using adhesives or other securing means.

Continuing with FIG. 51, outer diameter “D5” of the transition portion359 c and first outer diameter “D6” of the first portion 370 a of collar370 are both greater than outer diameter “D4” of body portion 359. Inembodiments, outer diameter “D5” of the transition portion 359 c is lessthan outer diameter “D6” of the first portion 370 a of collar 370.However, in alternate embodiments, outer diameter “D5” may be equal toouter diameter “D6.” In operation, the larger outer diameter “D6” of thefirst portion 370 a of collar 370 enables proximal articulation bar 358b to resist bending as the force/rotation transmitting/convertingassembly 350 converts and transmits a rotation of the proximal driveshaft 314 to an axial translation of the loading unit 300 (FIG. 48).This relationship is determined by the equation:

F _(B) =MR/I

where “M” is the moment, “R” is the radius of the object resisting theforce, and “I” is the moment of inertia.

With reference to FIG. 53, force/rotation transmitting/convertingassembly 350 further includes an articulation plate 354 a configured tosecure the distal force transmitting member 354 within the inner housingassembly 312. Articulation plate 354 a defines a through hole 354 bhaving a diameter “D9” configured for locating and supporting the firstportion 370 a of collar 370. The diameter “D9” of the through hole 354 bof the articulation plate 354 a is greater than the first outer diameter“D6” of the first portion 370 a of the collar 370 such that the matingof articulation plate 354 a and collar 370 reinforces collar 370 toresist bending of the proximal articulation bar 358 b.

Turning now to FIGS. 54-56, a force/rotation transmitting/convertingassembly 450, according to another embodiment of the present disclosure,is shown and will be described. Force/rotation transmitting/convertingassembly 450 is similar to the second force/rotationtransmitting/converting assembly 250, 350 and is only described hereinto the extent necessary to describe the differences in construction andoperation thereof. Likewise, another embodiment of an articulationbearing assembly is shown generally as 452. Articulation bearingassembly 452 is similar to articulation bearing assembly 252, 352 and isonly described herein to the extent necessary to describe thedifferences in construction and operation thereof.

With reference to FIG. 55, distal force transmitting member 454includes, an articulation bearing assembly 452, an articulation bar 458,and an inner sleeve 460. Articulation bearing assembly 452 includes abearing housing 452 a supporting an articulation bearing 453.Articulation bearing 453 includes an inner race 453 b that isindependently rotatable relative to an outer race 453 a. Outer race 453a and inner race 453 b each defines a circular cross-section.

In some embodiments, bearing housing 452 a has a non-circular outerprofile, such as, for example, a tear-drop shape. In embodiments, thebearing housing 452 a includes a racking assembly 380 (FIG. 57) similarto the one described above with reference to bearing housing 352 a. Inthis embodiment, racking assembly 380 enables bearing housing 452 a torack during actuation of the force/rotation transmitting/convertingassembly 450 without the stress from the racking being transferred tothe proximal drive shaft 414, thereby preventing bending of the proximaldrive shaft 414.

Articulation bar 458 extends along longitudinal axis “X” between adistal portion 459 a and a proximal portion 459 b. Distal portion 459 aof the articulation bar 458 is configured to connect to articulationlink 366 (FIG. 48) of loading unit 300. As will be discussed in greaterdetail below, proximal portion 459 b of the articulation bar 458 isdisposed between the inner race 453 b of the articulation bearing 453and the inner sleeve 460.

Inner sleeve 460 extends axially beyond the articulation bearing 453.For example, the articulation bearing 453 may define a length “L1,” andinner sleeve 460 may define a length “L2,” wherein length “L1” is lessthan length “L2.” It is envisioned that the longer aspect ratio of theinner sleeve 460 relative to the articulation bearing 453 will reducebending of the articulation bar 458 as it rotates about the longitudinalaxis “X” relative to the articulation bearing 453. Though the figuresshow inner sleeve 460 extending distally from articulation bearing 453,it is envisioned that inner sleeve 460 may also extend proximally fromarticulation bearing 453.

As shown in FIG. 55, inner sleeve 460 is supported within inner race 453b of articulation bearing 453. Accordingly, inner race 453 b defines aninner diameter “D10” and inner sleeve 460 defines an outer diameter“D11,” wherein inner diameter “D10” is greater than outer diameter “D11”such that an outer surface 460 a of inner sleeve 460 abuts an innersurface (not shown) of inner race 453 b.

In embodiments, the outer surface 460 a of inner sleeve 460 defines aslot 470 shaped for disposal of the proximal portion 459 b of thearticulation bar 458, e.g., proximal portion 459 b of the articulationbar 458 is disposed in slot 470 between inner sleeve 460 and inner race453 b. To secure the proximal portion 459 b of the articulation bar 458to the articulation bearing 453, the proximal portion 459 b of thearticulation bar 458 is welded into the slot 470. However, inembodiments, any appropriate means, such as for example, adhesives maybe used to secure the articulation bar 458 to the articulation bearing453. In embodiments, there may be a gap (not shown) between the proximalportion 459 b of the articulation bar 458 and a proximal face (notshown) of the slot 470 on the outer surface 460 a of the inner sleeve460. It is envisioned that the gap would enable a manufacturer to spacethe articulation bar 458 in relation to the articulation bearing 453with greater accuracy and repeatability.

With reference to FIG. 56, an inner housing assembly 412, similar toinner housing assembly 312, is shown. Inner housing assembly 412includes an electrical assembly 490 similar to electrical assembly 290.The electrical assembly 490 includes a slip ring cannula 499 supportedwithin inner sleeve 460 to protect and/or shield any wires extendingthrough slip ring cannula 499. Slip ring cannula 499 has an outerdiameter “D12” which is less than an inner diameter “D13” of the innersleeve 460 such that the slip ring cannula 499 engages the inner sleeve460 utilizing an interference fit.

Turning now to FIG. 58, a force/rotation transmitting/convertingassembly 550 according to another embodiment of the present disclosureis shown and will be described. Force/rotation transmitting/convertingassembly 550 is similar to the second force/rotationtransmitting/converting assembly 250, 350, and 450 and is only describedherein to the extent necessary to describe the differences inconstruction and operation thereof.

Force/rotation transmitting/converting assembly 550 includes a proximalrotation receiving member, such as, for example, a proximal drive shaft514 engagable with a respective rotatable drive shaft (not shown) of thesurgical device 100, a driver 560, and a distal force transmittingmember 554. The proximal drive shaft 514 extends along longitudinal axis“X” between a distal portion 514 a and a proximal portion 514 b. Theproximal drive shaft 514 member includes an outer surface 514 c defininga plurality of spur gears 514 d extending along the longitudinal axis“X.”

The driver 560 extends along longitudinal axis “X” between a distalportion and 560 a and a proximal portion 560 b. The driver 560 includesan outer surface 560 c defining a plurality of spur gears 560 dextending along the longitudinal axis “X” where the plurality of spurgears 560 d of the driver 560 are configured to engage the plurality ofspur gears 514 d of the proximal drive shaft 514. Accordingly, when theproximal drive shaft 514 is rotated relative to the driver 560 about thelongitudinal axis “X” in a direction given by arrow “A,” the driver 560is rotated in the opposite direction relative to the proximal driveshaft 514 about the longitudinal axis “X” given by arrow “B.”

With continued reference to FIG. 58, driver 560 includes an innersurface 560 e defining a bore 562 therethrough. The bore 562 defines aplurality of threads 562 a. Distal portion 560 a of the driver 560defines a protrusion, such as, for example, a distal boss 564.Similarly, proximal portion 560 b of the driver 560 defines aprotrusion, such as, for example, a proximal boss 566.

An inner housing assembly (not shown) similar to inner housing assembly312 and 412, includes a distal articulation plate 556 defining a firstthrough hole 556 a configured for locating the distal boss 564 of thedriver 560. When distal boss 564 is mounted into the first through hole556 a of the distal articulation plate 556, the driver 560 is co-axialto the longitudinal axis “X.” Distal articulation plate 556 alsoincludes a second through hole 556 b configured for locating andsupporting a distal protrusion 516 extending from the distal portion 514a of the proximal drive shaft 514.

When the distal boss 564 of the driver 560 is located in the firstthrough hole 556 a and the distal protrusion 516 of the proximal driveshaft 514 is located in the second through hole 556 b, the plurality ofspur gears 560 d of the driver 560 are engagable with the plurality ofspur gears 514 d of the proximal drive shaft 514. The housing (notshown) also includes a proximal core portion 520 configured for locatingthe proximal boss 566 of the driver 560. The proximal core portion 520includes a through hole 520 a configured to locate the proximal boss 566of the driver 560 such that the driver 560 is co-axial to longitudinalaxis “X.”

Continuing with reference to FIG. 58, the distal force transmittingmember 554 includes a sleeve 552 and an articulation bar 558. Sleeve 552includes an outer surface 552 a defining a plurality of threads 552 bconfigured to engage with the plurality of threads 562 a defined in thebore 562 of the driver 560. Sleeve 552 also includes an inner surface552 c defining a bore 553 therethrough. Articulation bar 558 extendsalong longitudinal axis “X” between a distal portion 559 a and aproximal portion 559 b. The proximal portion 559 b of the articulationbar is secured to the inner surface 552 c of the sleeve 552 such thatwhen the sleeve is threadingly connected to the driver 560, thearticulation bar 558 is co-axial to longitudinal axis “X.”

In operation, as the proximal drive shaft 514 is rotated about thelongitudinal axis “X” in the direction given by arrow “A,” the pluralityof spur gears 514 d engages the plurality of spur gears 560 d of thedriver 560 to rotate driver 560 about the longitudinal axis “X” in thedirection given by arrow “B.” As driver 560 rotates, the sleeve 552 ofthe distal force transmitting member 554 is axially translated,resulting in axial translation of the loading unit 300 of surgicaldevice 100.

In accordance with the present disclosure, an overall length of adapterassembly 200 has been reduced as compared to prior adapter assembliesthat have been developed to transmit/convert forces/rotations fromsurgical device 100 to loading unit 300. By reducing an overall lengthof adapter assembly 200, a center of gravity of an assembled surgicaldevice 100, adapter assembly 200 and loading unit 300 has been shiftedproximally as compared to a center of gravity of an assembled surgicaldevice 100, a prior adapter assembly and a loading unit 300. As such, alevel of comfort to the end user in using the electromechanical surgicalsystem of the present disclosure has been increased, and a level offatigue has been decreased.

In operation, when a button of surgical device 100 is activated by theuser, the software checks predefined conditions. If conditions are met,the software controls the motors and delivers mechanical drive to theattached surgical stapler, which can then open, close, rotate,articulate or fire depending on the function of the pressed button. Thesoftware also provides feedback to the user by turning colored lights onor off in a defined manner to indicate the status of surgical device100, adapter assembly 200 and/or loading unit 300.

Reference may be made to U.S. Pat. No. 7,819,896, the entire contents ofeach of which are incorporated herein by reference, for a detaileddiscussion of the construction and operation of loading unit 300, asillustrated in FIGS. 1 and 48.

Any of the components described herein may be fabricated from eithermetals, plastics, resins, composites or the like taking intoconsideration strength, durability, wearability, weight, resistance tocorrosion, ease of manufacturing, cost of manufacturing, and the like.

It will be understood that various modifications may be made to theembodiments of the presently disclosed adapter assemblies. Therefore,the above description should not be construed as limiting, but merely asexemplifications of embodiments. Those skilled in the art will envisionother modifications within the scope and spirit of the presentdisclosure.

1. (canceled)
 2. A force/rotation transmitting/converting assembly forinterconnecting a drive shaft of a surgical device and an axiallytranslatable drive member of a loading unit, wherein the force/rotationtransmitting/converting assembly includes: a bearing assembly having afirst through hole and a second through hole, the first through hole andthe second through hole intersecting to define a cavity configured forhousing a ball having a threaded bore formed therein, the threaded boreconfigured for threadably connecting to a threaded portion of the driveshaft of the surgical device.
 3. The force/rotationtransmitting/converting assembly according to claim 2, wherein thebearing assembly includes an outer race connected to a distal end of thedrive shaft of the surgical device.
 4. The force/rotationtransmitting/converting assembly according to claim 3, wherein the outerrace is threadably connected to a threaded distal end of the drive shaftof the surgical device.
 5. The force/rotation transmitting/convertingassembly according to claim 2, wherein the threaded bore is configuredfor threadably connecting to a distal end of the drive shaft of thesurgical device.
 6. The force/rotation transmitting/converting assemblyaccording to claim 2, wherein the bearing assembly includes an innerrace and an outer race.
 7. The force/rotation transmitting/convertingassembly according to claim 6, further comprising an inner sleevesupported at least partially within the inner race of the bearingassembly and extending axially from the inner race.
 8. A force/rotationtransmitting/converting assembly for interconnecting a drive shaft of asurgical device and an axially translatable drive member of a loadingunit, wherein the force/rotation transmitting/converting assemblyincludes: a receiving member that is connectable to a drive shaft of thesurgical device, the receiving member including at least one spur gear;a driver including at least one spur gear configured for mating with theat least one spur gear of the receiving member, the driver defining abore therethrough; and a force transmitting member that is connectableto a portion of the axially translatable drive member of the loadingunit, the force transmitting member including: a sleeve configured tomate with the driver; and an articulation bar configured to selectivelyengage the axially translatable drive member of the loading unit.
 9. Theforce/rotation transmitting/converting assembly according to claim 8,wherein the force/rotation transmitting/converting assembly converts andtransmits a rotation of the drive shaft of the surgical device to arotation of the driver such that the sleeve of the distal forcetransmitting member is axially translated resulting in an axialtranslation of the axially translatable drive member of the loadingunit.
 10. The force/rotation transmitting/converting assembly accordingto claim 8, wherein the bore of the driver defines at least one thread.11. The force/rotation transmitting/converting assembly according toclaim 10, wherein the sleeve includes at least one thread configured tomate with the at least one thread of the bore of the driver.
 12. Theforce/rotation transmitting/converting assembly according to claim 8,wherein a proximal end of the articulation bar is secured to the sleeve.13. The force/rotation transmitting/converting assembly according toclaim 8, wherein the force transmitting member is connectable to anarticulation link of the axially translatable drive member of theloading unit.
 14. The force/rotation transmitting/converting assemblyaccording to claim 8, wherein a proximal end of the articulation bar issecured to the sleeve, and wherein a distal end of the articulation baris configured to selectively engage the axially translatable drivemember of the loading unit.
 15. The force/rotationtransmitting/converting assembly according to claim 8, wherein thesleeve defines a bore therethrough which defines an inner surface, andwherein a proximal end of the articulation bar is secured to the innersurface of the sleeve.